CN101722223B

CN101722223B - Roll-former apparatus with rapid-adjust sweep box

Info

Publication number: CN101722223B
Application number: CN2009102541453A
Authority: CN
Inventors: 布鲁斯·W·莱昂斯; 布莱恩·E·古尔德; 詹姆斯·H·多德; 理查德·D·海因茨
Original assignee: Shape Inc
Current assignee: Shape Inc
Priority date: 2005-06-13
Filing date: 2006-06-09
Publication date: 2012-11-28
Anticipated expiration: 2026-06-09
Also published as: CN101722223A; CA2611484A1; WO2006138179A2; JP5718400B2; AU2006259662A1; EP1890829A2; RU2405644C2; JP2013154405A; US20060277960A1; RU2008101438A; JP5344914B2; EP1890829A4; MX2007015482A; JP2008543571A; KR20080032091A; CN100584479C; EP1890829B1; ES2572982T3; US20080047315A1; US20080053178A1

Abstract

A computer controlled roll forming apparatus (19) is adapted to provide a repeating pattern of different longitudinal shapes to a continuous beam ''on the fly'' during the roll forming process. A sweep station (20) on the apparatus includes a primary bending roller tangentially engaging the continous beam (21)along the line level and an armature (35, 61) for biasing the continous beam against the primary bending roller (62) for a distance partially around a downstream side of the primary bending roller to form a sweep. Further, actuators (50) adjustably move the armature at least partially around the downstream side of the primary bending roller between at least first and second positions for imparting multiple different longitudinal shapes into the continuous beam. In one form, the apparatus also includes a coordinated cut-off (22), so that when separated into bumper beam segments (21), the ends of the individual beam segments have a greater sweep than their center sections.

Description

A kind of roll forming method

The application is 200680021146.8 divides an application of submitting on June 9th, 2006

Technical field

The present invention relates to a kind of rolling formation apparatus, it has the bending station of a plurality of bendings (being different longitudinal curvatures) being given the roll forming bar.

Background technology

The bumper rail of roll forming has obtained accepting extensively in vehicle bumper system recently, because their low cost and high dimensional accuracy and repeatability.They popular owing in roll forming bar part crooked (buckling promptly is provided) increase with the performance that better aerodynamic appearance is provided.For example at Sturrus5, disclosed a kind of vertically method of constant bent stick of roll forming that is used in 092,512.

The aerodynamic appearance of vehicle bumper is usually through forming the part of front surface backward in the end of bumper with the speed that increases from the central authorities of said bumper rail.This is accomplished by the auxiliary operation on bumper rail usually.The auxiliary operation of exemplary prior art that is used for accomplishing these is at Sturrus5, (its disclosed tubular rod distortion/end crushes) shown in 092,512; And at Sturrus6; (it has disclosed bar and the cut end that is connected support) shown in 240,820 is at Heatherington6; (it has disclosed the molded element that the end connects) shown in 318,775; At McKeon6,349,521 (they have disclosed the tubular rod that reshapes), at Weykamp6,695,368 and Reiffer6, (it has disclosed the metallic support that the end connects) shown in 042,163.Yet auxiliary operation has increased cost, improved dimensional variability and has increased the stock during handling, and shows quality problems.It is desirable to eliminate need to form and had the auxiliary operation that increases crooked bumper ends backward.Simultaneously, the vehicular manufacturer wants the flexibility keeping low cost and bumper beam designs is provided.Therefore, there is the requirement of contradiction, reserves improved space of the present invention and needs like this.

The known computer control that is provided for crooked and roll forming apparatus.Referring to Berne4,796,399, Kitsukawa4,624,121 and Foster3,906,765.The also known bumper rail that wherein forms with most footpaths.For example, referring to Levy6,386,011 with japanese document JP61-17576.In addition, known through conjugation tube make pipe and bar around the arc-shaped outer surface bending of plate-like axle with tube portion be wrapped in around the axle, up to the required permanent deformation of generation.For example, referring to Miller1,533,443 and Sutton5,187,963.But; The bumper rail that importantly is used for modern vehicle shows a large amount of difficult points because their relatively large cross sectional dimensions and non-circular transverse cross-section, employed high-strength material, vehicular manufacturer's very strict size and error requirements, car manufacturing factory cost competition and the high speed of modern roll forming line operation.

Be noted that the existing bending mechanism on roll forming apparatus processes adjustable usually.For example, Sturrus5,092,512 has disclosed a kind of manual adjustable bending station.(referring to Sturrus5, it is capable that the Figure 10-11 and the 6th in 092,512 is listed as 1-9).Yet,, be not to mean that device can make and have the crooked bar in most footpaths even bending station is adjustable.For example, because at Sturrus5, the bending station in 092,512 can manually be adjusted, and as practical problem, can not enough adjust to allow in single unit vehicle bumper rail part, to form evenly spaced differently curved soon.Mostly just approximately the 4-5 foot is long to be noted that bumper rail, and the linear speed of roll forming can reach the 4000-5000 foot/hour, thereby crooked any variation must repeatedly be accomplished relatively fast and in a large number.Definitely, different bucklings can not repeat through the length of manual mode along continuous bar uniformly, and can not be in the high speed roll forming operation of using the slow motion automatic pilot fecund and carrying out efficiently.Therefore; Depositing for making the method for roll forming bar with different radii (part of in other words handling as roll forming synchronously) and the demand of rolling formation apparatus along its length " apace "; Wherein said method and apparatus does not need a large amount of auxiliary operation (or the less aid in treatment of their needs) at least, for example cuts, fixes, the back roll forming of welding, assist formation and/or support connects.

Renzzulla patent 6,820,451 discloses a kind of power-adjusted sweep station.As best understanding; Renzzulla patent 6,820,451 has disclosed a kind of bending station adjusted that is used for rolling formation apparatus; Wherein upstream rollers 16 is followed by the adjustable component 14 of adjustable support; Assembly 14 is combined with the adjusting of first's (being used for crooked coarse regulation) of principal curvature roller 18, formation bending mechanism and pushes roller 20 and form the second portion help roll 22 of (being used for crooked meticulous adjustment) (20-22 referring in the 14th row in the Renzzulla patent 6,820,451 is capable).In Renzzulla patent 6; 820; Following home roll 18 in 451 (being the roller on the downstream/convex side of bent stick) is preferably placed at the level of linearity face top of bar of roll forming (referring to Fig. 1; " deflection roller 18 in the vertical directions are higher than the level of linearity face ", are listed as the 65th row referring to the 10th and are listed as the 1st row) to the 11st.Second roller 20 (i.e. roller on the recessed side of bending roll) be supported be used for around the axle (bar 90) of first roller adjustably arcuate movement (referring to Figure 15-16) to the difference adjustment position that is used for pressure is on the continuous rolling shaped bar.The actual flexure of bar takes place at 143 places, position at the upper reaches of roller 18/20.(it is capable to be listed as 45-46 referring to the 12nd).Control Component 130 is used for making roller 20 to move along its adjustment curved path.(being listed as the 62nd row and Fig. 1-2) referring to the 8th.Auxiliary stand assembly 110 is oriented to be adjusted at the roller 22 on the main support assembly 14, and can adjust through the operation of adjustment assembly 137.This patent is pointed out not only can carry out " apace " adjustment (being listed as the 4th row referring to the 14th) but also can carry out coarse regulation and meticulous adjustment respectively to master component and accessory part.(being listed as the 22nd row) referring to the 14th.

Although in Renzzulla patent 6; 820; The equipment that discloses in 451 obviously can carry out the power adjustment in the rolling formation apparatus operation; Instruction or suggestion below the inventor does not find in Renzzulla patent 6,820,451; Promptly provide control/timing to adjust function and Collaborative Control function, be used for repeatedly adjusting equipment in the scope of the length of single bumper section (promptly along the length of the continuous bar of roll forming in the scope of measured about 4-5 foot) and along the selected relative position place of this length so that differently curved (being different radii) of a series of repetitions to be provided.In addition; In Renzzulla patent 6; 820; Do not have the use a computer bending apparatus of control of instruction to form many bent stick in 451, this bending apparatus links to each other with collaborative computer-controlled shearing device, and this shearing device is used in the specific location relevant with the specific curvature zone single bumper rail partly being cut away from continuous bar.In addition, (also be based on Renzzulla patent 6,820 based on thread density by Fig. 1-2 suggestion; Any disclosure of not adjusting in 451) about automatic operation " circulation "; Look that the device in Renzzulla patent 6,820,451 also receives the puzzlement of the problem of manual adjustment bending station; Promptly can not enough adjust in the scope of 4-5 foot, to form a plurality of bendings soon, suppose under the situation of roll former normal phase linear speed fast along the continuous rolling shaped bar.

When tight bending (bending that promptly has minor radius) is provided along continuous bar, in the bending station in the Renzzulla patent 6,820,451, there is another basic problem potentially.Renzzulla patent 6; 820; 451 relate to bending station, and wherein first relative fixed (master) forming rolls 18 is positioned in the level of linearity face top (be listed as the 65th row referring to the 10th and be listed as the 1st row to the 11st) of continuous bar, so that continuous bar is from its level of linearity facial disfigurement; And disclose second movable/can adjust and push roller 20; Its axle around first relative fixed (master) roller 18 can be adjusted along curved line, so that make bending force be in 143 places, position in home roll 18 the place aheads (upper reaches) ..., upstream position 143 is between the upstream and downstream backing roll 16 of home roll 18 usually.(it is capable to be listed as 45-46 referring to Figure 16 and the 12nd).When the bending mechanism of Renzzulla is adjusted to form tighter bending (i.e. the more bending of minor radius).Bent position 143 further upstream and away from home roll 18 ground is moved potentially.Through bar being bent at unsupported upstream position 143 places and being out of shape, the bar wall is crooked with non-control mode effectively.Make very difficult control distortion and complications advance like this, be difficult to control unwanted winding and skew, also be difficult to controlling dimension and change.These variable combination together and produce the unpredictability of the distortion on bar and the bar wall.In other words, when support distances does not increase (when forming tight bending), the non-controlled motion of bar wall and the problem of distortion become serious more ..., form size and quality problems potentially.Make up such problem and be that the diameter of roller 16 makes roller 16 away from roller 18 and 20 location ..., cause like this roller 16 with 18 against the contact point of bar relatively large distances at interval, this distance be substantially equal to that roller 18 and 20 rotates above that spool between distance.Non-control ground skew and crooked when big so not support distances allows the wall of roll forming bar in not having the zone of supporting, to deform.

The system that thus, need have above-mentioned advantage and address the above problem

Summary of the invention

In one aspect of the invention, an equipment comprises that being used for the plate of material roll forming is the rolling formation apparatus with continuous bar of vertical linear horizontal plane, and said continuous bar has first surface and opposing second surface; Said device also comprises bending station, and itself and said level of linearity face are point-blank and be used on said continuous bar, forming longitudinal shape.Said bending station comprises that the principal curvature roller that tangentially engages along said level of linearity face and said continuous bar keeps said continuous bar tightly to abut against said principal curvature roller to form crooked annex with being used on a segment distance in the downstream that partly centers on said principal curvature roller.Said device also comprises actuator, and move in the downstream that this actuator is used for making annex be centered around the said principal curvature roller between first and second positions at least in part, to give said continuous bar with at least the first and second different longitudinal shapes respectively.

In another aspect of the present invention, a device comprises roll forming device, and it is used for the plate of material roll forming is the continuous bar with level of linearity face, and said continuous bar has first surface and opposing second surface.Bending station and said roll milling apparatus and be positioned at the downstream of said roll milling apparatus and are used for making continuous bar to form longitudinal shape point-blank.Said bending station comprises first roller and second roller relative with said first roller, and this second roller and said first roller be relatively being engaged in said continuous bar therebetween, and comprises the mechanism of the position that is used for controllably adjusting said second roller.When the said continuous bar of roll forming, said first roller is oriented to tangentially engage and remain on relatively-stationary position with the first surface of said continuous bar.Said second roller is oriented to tangentially engage with the said second surface of said continuous bar.Said first roller limits first rotating shaft; Said second roller can be moved by said mechanism along curved line around adjustable axle; Said adjustable axle be positioned at said continuous bar with said first identical side and be in said first or said first upstream end; Thereby when adjustment, said second roller is towards more moving the position in downstream with respect to said first roller.

In another aspect of the present invention, it comprises an equipment: bending apparatus, and it comprises and is used for the axle of backing roll that this roller is used for making continuous bar to form bending; Annex is operably mounted on the fixed axis in the said axle, and said annex supports and makes said continuous bar form at least one specific axis in the crooked said roller.Automatically the adjusting device of the operation angle position that is used for repetition and adjusts said annex exactly makes a said specific roller automatically move towards the different downstream positions with respect to another roller to give the bending to said continuous bar with change on said continuous bar, to form the repeat patterns of longitudinal shape, to comprise.

In another aspect of the present invention, a device comprises bending apparatus, and it has the principal curvature roller that engages with continuous bar tangential.Relative maintenance roller is adjustable at the diverse location in the downstream of said principal curvature roller and keeps said continuous bar to abut against said principal curvature roller, required bending is given said continuous bar.At least one stable roller tangentially engages said continuous bar at the upper reaches of said principal curvature roller.First, second drives said principal curvature roller, said maintenance roller and said stable roller respectively with the 3rd CD-ROM drive motor.Controller control independently said first, second with the 3rd roller in each speed, with the stress on control and the said continuous bar of management in said bending station, so that form the more consistent curved shape of said continuous bar.

In another aspect of the present invention, a method may further comprise the steps: provide to have the high-strength material plate of the tensile strength of 80KSI at least; The rolling formation apparatus that can form said plate of material with about at least 900 feet/hour speed is provided; Said rolling formation apparatus comprises can adjust bending station, actuator and controller, and this controller links to each other with actuator to adjust said bending station automatically and apace to form differently curved radius with the said bending station of adjusting; And the continuous bar that said plate of material roll forming is had continuous cross section with formation; In roll forming and near roll forming finishes; Continue and repeatedly give differently curvedly, carry out said roll forming with about at least 900 feet/hour linear speed simultaneously.

Apparatus of the present invention relate to bending station; Wherein the continuous bar of roll forming is received by first forming rolls and tangentially engages with first forming rolls; Then around stationary roll pulling or " winding " continuous bar; Bite is moved in downstream through around home roll circumferentially, obtains enough permanent deformations will keep required amount of bow up to continuous bar.Apparatus of the present invention are paid close attention to home roll at the continuous bar of tangential position place clamping, home roll tangentially with the horizontal plane of continuous bar point-blank.Apparatus of the present invention provide member; When the continuous tangential of continuous bar/circumferencial direction ground engages home roll; This member is used for continuous bar part is centered around around the stationary roll in downstream of home roll; Between the adjustment period of the crooked function of continuous bar any, move along circumferencial direction towards the downstream of home roll round stationary roll in the biting point.

Explanation, claim and accompanying drawing below the research will understand and appreciate these and others, target and characteristic of the present invention.

Description of drawings

Fig. 1 comprises the roll former of realizing bending station of the present invention and crooked controller.

Fig. 2-2A is for having exemplary bar differently curved and that processed by the roll former of Fig. 1 along its length.

Fig. 3 is the perspective view of the bending station of Fig. 1.

Fig. 4 is and the similar perspective view of Fig. 3 still only to show four home rolls of the bending station of Fig. 3.

Fig. 5-8 is the side, end face of the bending station of Fig. 3, (downstream) and front (upstream side) at the back.

Fig. 9-9A is the side view of four home rolls of Fig. 4, and Fig. 9 shows the roller that is positioned to through the linear bar part, and Fig. 9 A shows the roller that is positioned to form bent stick.

Figure 10-11 is the side view of the bending station of Fig. 3; Figure 10 shows to be adjacent to and is used for forming the tightly bending station of the position of bending (having minor radius) in the bar continuously, and Figure 11 shows and is adjacent to the bending station that is used in continuous bar, forming the position of more shallow bending (having than major diameter).

The specific embodiment

Roll forming machine 19 of the present invention (Fig. 1) is used to form the vehicle bumper 21 ' (being also referred to as " bumper rail section " or " bracing piece " here) of roll forming; It has constant shape of cross section and consistent size shape, but has the different longitudinal curvatures that form at bending station 20 places.Bending station 20 be arranged to rolling formation apparatus 19 point-blank and at the port of export of rolling formation apparatus 19.The roll forming of rolling formation apparatus 19 part and Sturrs 5,092,512 in Fig. 4 shown in the roll forming part different, and the instruction of 5,092,512 patents of Sturrs is whole is incorporated in this.The multiple roll system that bending station 20 of the present invention comprises by computer control and automation mechanized operation and is arranged to allow quick and precisely adjust; Permission repeats to carry out bending operation with changing during the roll forming processing, so that whole a part of length along the bar section of handling as roll forming forms even and different bending radius.Collaborative/timing turning off device 22 is operably connected to computer control and is used for continuous bar 21 is cut into the bumper rail section 21 ' that is used for vehicle bumper system.Through be applied to the length and the time of the bending on the bar 21 based on the part Position Control; For example, independent bumper rail 21 ' can be provided with the end parts and the middle body with the degree of crook (promptly bending is littler on radiator/barrier zone) that reduces of the degree of crook (promptly bigger in the bending of dashboard place) with increase.Recognize when using identical roller and using identical bumper part and only be under the situation of bending change; Can accomplish through computer control " apace " from a bar profile to another bar profile varying; Eliminated the instrument transformation time thus; Eliminated installation time, and eliminated " starting " time (scrap).Bending station of the present invention is illustrated with " C " shape bar and links to each other, but recognizes and can also use " W " shape bar part, or " D " or " B " shape bar, or is used for making other bar part.

Shown roll forming section bar 21 ' (Fig. 2) is a C shape; And comprise end parts 21A with

radius R

1 and 21B and for linear (Fig. 2) (be radius equals infinitely great) or have different middle body 21C, and have transitional region 21D and the 21E that connects middle body and end parts than major radius R2 (Fig. 2 A).In the bar 21 ' of reality, radius R 1 can be fully different with those radiuses shown in the 2A unlike Fig. 2 with R2, but example shows the performance of apparatus of the present invention.Equally; Recognize that crooked radius can be made into the whole consistent length ground variation (being that middle body can not have single continuous radius R 2) along bar 21 '; And/or will have the central authorities of connecting rod and a plurality of " mixing " transitional region of end, and/or middle body can be linearity (or even crooked on the contrary).Recognize that bumper rail of the present invention part can process by having the sufficient intensity that plays the effect of car insurance lever and any material of performance.Shown bumper beam material is unimach (UHSS) plate of material, and it has 80KSI or higher tensile strength, or preferably has the tensile strength of 120KSI at least, but tensile strength can be 220KSI or higher (for example, martensite steel material).

Shown rolling formation apparatus can reach the linear speed of 500 feet/hour (or higher), and is used to form tubulose or unlimited bar part, and this bar for example partly has the sectional dimension up to 4 * 6 inches (greater or lesser).Shown bending station 20 (Fig. 1) and rolling formation apparatus (machine) are provided with point-blank and are in an end of rolling formation apparatus.It is contemplated that out and can use different shearing devices.For example, referring at 5,305 of Heinz, the shearing device shown in 625,5,305,625 instruction and the disclosure content integral body of Heinz are incorporated in here.The shearing device 22 of apparatus of the present invention comprises shearing-type cutter blades 22 ', and the actuating of shearing-type cutter blades 22 ' can be controlled by computer control 56 (or Collaborative Control device), thereby bumper rail 21 ' can cut at the key position place along continuous tubular rod 21.Shown shearing device 22 is programmed to cut off in the middle of the part of extension and the tight bending (tight sweep) in bumper rail 21 '; Half one of tight thereby crooked (for example part 21A) locates to finish at each continuing insurance lever 21 ', and another part (for example part 21B) finishes at the other end place of each continuing insurance lever 21 '.Shearing device be positioned at bending station " downstream " but relatively with its next-door neighbour so that save the space, and leave the unfavorable winding backward that reduces continuous bar when being bent to form the station at bar continuously.Shearing device 22 is by computer control, thereby bar 21 ' has the symmetry of required end to the end when separating with continuous bar 21.If desired, can recognize that shearing device self can be bonded on bending station in the position near the end that forms crooked adjustable roller.For example, shearing device can be connected to sub-frame 35 and move with sub-frame 35, and is as described below.

Bending station 20 (Fig. 3 and 4) comprises pedestal or main frame 23, and pedestal or main frame 23 comprise horizonal base plate 24 and the vertical installing plate 25 that is fixedly connected.Increase one or more stabilizer plates 25A and bridge 25B and come

steadying plate

24 and 25 and keep their relative right angles.The first half ones 26 of bending station 20 comprise the top axle 27 and bottom axle 28 that is loaded with forming

rolls

60 and 61 respectively, and top bearing 29 is pivotally mounted to

axle

27 and 28 on the vertical plate 25 respectively with bottom bearing 30, are used for supporting forming rolls 60 and 61.Apex roller 60 is called as the principal curvature roller, because apex roller 60 is that bar 21 is around its crooked fixed axle roller.The axle 27 of apex roller 60 is the axle of lower roller 61 around it, and sub-frame 35 rotates with instantaneous change crooked adjustably.Lower roller 61 is called as annex below with sub-frame 35.They also are called as maintenance equipment, because they move bar 21 is being held against principal curvature roller 60 crooked on bar 21, to form around principal curvature roller 60 adjustably.

Top bearing 29 is through threaded support 29A vertically adjustment manually, so that manually change the distance (promptly changing the biting pressure of roller) between axle 27 and 28.Similarly manual adjustment designs is known in the prior art, and is used in the roll forming mechanism to hold the different size roller die that is used to form different size bar cross section.Be noted that; Adjustment is manually carried out as the part that rolling formation apparatus is set usually; And at the initial run duration of rolling formation apparatus, the mode of usually not carrying out and repeated flex profile crooked with constant variation as the part of the production operation of rolling formation apparatus forms bending.

Pith of the present invention is automatic " circulation " adjustment performance and the adjustment fast/accurately of bending station 20 " the second half one " assembly 30A (Fig. 4).The second half 30A of comprise the rigidity sub-frame 35 (also being the part of " annex ") that is positioned at adjustably between the main vertical plate 25.Sub-frame 35 has inversion " U " shape and comprises and being fixed together as vertical plate in a couple of stiff member 36 and spacer block 38.Interior vertical plate 36 is installed in rotation on the top axle 31 through bearing 33A.Top axle 31 vertically can be adjusted on the vertical plate 25 outside, is similar to very much top axle 27 and in the first of bending station, vertically can adjusts, so that change the biting pressure of roller.The lower end of vertical plate 36 in bottom axle 32 is installed in bearing 34.Sub-frame 35 outside on the axle 31 between the vertical plate 25 angle rotatable ground adjust.When rotated, the lower roller 63 bottom sub-frame 35 makes bottom axle 32 and is installed on the axle 32 moves to the reposition (referring to Fig. 9 and 9A) in the downstream of the apex roller 62 on top axle 31 along curved line P1 (Fig. 9 A).In angle adjustment position (Fig. 9 A), the lower roller 63 in the second half 30A of makes continuous bar 21 fully around portion's roller 62 local windings in advance, so that bar 21 is obtained permanent arc-shaped deformation (being longitudinal curvature or bending) continuously.In other words, lower roller 63 is effective as maintenance equipment and keeps continuous bar 21 with the circumferential surface of selected distance against (or adjacency) apex roller 62, because extend through (promptly centering on) roller 63 continuously bar 21 tangent lines.

The position of the angular movement of annex (being sub-frame 35 and roller 61) and the time of time and shearing device 22, controller 56 was through loop 55 (Fig. 4) control actuating system by controller 56 controls." winding " action of roller 63 provides simple and short motion on every side when roller 63 moves around roller 62; This motion forms the excellent dimensions control and the uniformity of the bar section 21 ' that processes, thus bar section 21 ' be symmetry and can have relatively compact bending in each end.The wall of bar 21 is preferably supported by master (top) roller 62 during bending process well continuously, because bending begins to take place near apex roller 62 places at apex roller 62 places or very, and further when bar 21 quilts are around apex roller 62 drawings continuously, is further taken place.Careful and rapid adjustment through sub-frame 35; Continuously bar 21 finishes with the mode with predictable many curved shapes, and bar 21 has been eliminated a large amount of essence aid in treatment so that the needs that the end of bar 21 ' is out of shape backward afterwards being cut into bumper rail section 21 ' continuously.

Especially, when precipitous relatively bending (being that minor radius is crooked) formation, need carry out maximum control on the bar 21 continuously.This is using superhigh intensity and/or when differently curved needs especially when being endowed continuous bar 21, because these bigger change in size of generation on wall easily.Be noted that axle 31/32 preferably is positioned to be positioned as close to

axle

27 and 28 at work, thereby the distance between roller is minimum.Certainly,

roller

60,61,62 and 63

size impact axle

27,28,31 and 32 can be positioned to lean on how closely.Be noted that sub-frame 35 also makes bottom axle 32 away from another bottom axle 27 ground motion along the angle adjustment of path P 1 (Fig. 9 A).In order between

lower roller

61 and 63, extra support to be provided, service bridge shape support member (sliding-type support member or many colyliforms roller support member) can join between

roller

61 and 63, to support the bottom and/or the side of continuous bar 21 with being described below.Be provided with under the situation of roller-type support, the roller support member can be around level or vertically rotating shaft rotation, and the wall that level or vertical rotating shaft are parallel on the supported bar 21 extends.(in other words, the rolling support member of supporting side walls rotates around vertical axes, and the rolling support member of support base wall rotates around trunnion axis.)。Be noted that other support member can be added into the upper reaches or the downstream of

critical rollers

62 and 63.

Importantly to note through making tensile stress maximization during the bending forming deflection and during the bending forming deflection compression stress is being minimized " skew (wondering) " that make the different walls on bar 21 continuously, twisting, crawl and unsteered deflection back and forth minimizes.We (inventor) finds that the drive that on each, is used for drive roller 60-63 can have very favorable effect.Through driving each roller 60-63, can optimally control along the stress of the different walls of continuous bar 21 with optimum speed.A reason of importance that is noted that the rotary speed of the single roller of independent control is should by with how many speed drive because be not easy to calculate exactly single roller usually.For example, apex roller 62 can be along top wall and along base wall contact lever 21, thereby in the contact point one must be necessary to slide very in a small amount.Secondly, when bending is imparted into continuous bar 21, roller 62 will change according to bending with 63 rotary speed.In addition, the different cross section shape will receive synthetic bending force during bending process, thereby some on-the-spot adjustment (on-the-floor) of axle speed will be necessary, and the operation roller milling train is to confirm optimal setting simultaneously.Compression stress is minimized, because compression stress (not being tensile stress) makes the wall formation of bar be difficult to fluctuating and the waveform of predicting or controlling more easily.Therefore, independent drive motors allows roller with (difference) speed rotation separately, and this roller " is pulled out top and the bottom section of bar 21 " through bending station, but does not cause any roller slip or rotate or " fight " each other.Be used for out-of-alignment and drive and can control independently through computer control, this computer control operationally links to each other with roller mill, thereby the whole Collaborative Control of machine is possible, comprises all aspects of bending station.

In structure shown in Fig. 3, each

axostylus axostyle

27,28,31 and 32 is by stepless speed-change driver (for example servo motor) single driving through controller 56 controls.Speed changes in response to the pre-programmed sequences and the timing routine that are input in the controller 56 during roll forming is handled soon.The speed that the speed that can recognize

disalignment

27,28,31,32 and roll forming are handled and roller on rolling formation apparatus with respect to continuous bar 21 (promptly by

roller

62 and 63 give bar 21 degree of crook influenced) the position relevant.A plurality of differently curved be formed on (early than bar section 21 ' is separated with continuous bar 21) in the single bumper rail section 21 '.As alternative, can little by little increase or reduce bending (rather than constant radius is crooked).Through making driving mechanism control independently with axle speed and make in the roller speed of the tangential direction at bending station place differently, can realize better on the bending radius and more consistent control with rolling formation apparatus.Recognizing for apparatus of the present invention does not need help roll, though can increase by one, if necessary.Recognize that roller 63 will be through the servo-driver control by controller 56 controls with respect to the angle position of roller 62.Servo-driver and controller are provided at the speed controlling in the loop that combines with the rolling formation apparatus one, and this speed is as the programmable feature of controller.

Shown support member can be set to the form of slip " bridge shape " support member 70 (Fig. 9 A).Support member 70 has substantially the arcuate shape with the curved front coupling of lower roller 63.Particularly, bridge shape support member 70 by below (and/or horizontal expansion) support from the fixed structure 71 that bridge shape support member 70 extends to main frame 23.The top of bridge shape support member 70 can comprise the smooth hard backing material that can be sliding engaged to the lower surface of continuous bar 21.As alternative; The top of shown bridge shape support member 70 can comprise the less relatively roller pin shape roller of diameter (for example diameter is an inch or two inches), and this roller pin shape roller engages and support continuous bar 21 in the position near

roller

62 and 63 with continuous bar 21 rollings.Additional backing roll can be positioned in the position of

roller

62 and 63 fronts or back and the engage sides of continuous bar 21.These additional rollers will have the rotating shaft of vertical extension, and can have less diameter.Shown bridge shape support member 70 has curved forward surface and back surface, thereby it can locate to such an extent that be positioned as close to

lower roller

61 and 63.

In addition, recognize that support member can be arranged on tubular rod inside by the stable inner axis of heart of upper reaches fixator (referring to the fixator 72 of Fig. 1) (being similar at Sturrus5 the snake shape inner axis of heart of instruction in 092,512).Be noted that inner axis of heart not necessarily, particularly for the open beam part and/or have and lack depth dimensions relatively and/or have the bar part of minimum bend (that is, limiting larger-diameter bending) for most of bumper cross sections and crooked speech.

A pair of actuator 50 (Fig. 3) is operably connected between main frame 23 and the crooked sub-frame 35, is used for angle ground adjustment sub-frame 35, arranges a brake 35 in a side of sub-frame 35.Each brake 50 comprises that an end is installed to the cylinder body 51 (Fig. 5) on the top of sub-frame 35, and is included in extensible/collapsible excellent 52 that the opposite end is connected to pedestal 23.When rod 52 shrank, sub-frame 35 rotated on axle 31, therefore changed the relative angle position of sub-frame 35 around axle 31.(comparison diagram 9 and 9A), because rotating shaft is in the center of top axle 31, stress is optimally located in location downstream as far as possible, wherein the home roll in bending station provides the excellent support for continuous bar 21.Actuator 50 can be connected to the hydraulic circuit 55 (Fig. 3) that is used for providing to cylinder body 51 (but balance) hydraulic fluid of variation.Hydraulic circuit 55 comprises motor or the pump that is operably connected to computer control 56 and is controlled by computer control 56, is used for controlling synergistically with rolling formation apparatus 20 extension and the contraction of brake 50.(the out-of-alignment driving that computer control 56 is gone back the control roll milling train and is used for bending station).Sensor can be positioned on the bending station as required, be used for sensing sub-frame 35 the position and/or be used for continuous bar 21 the position (locating hole that for example increases in bar 21 by device 19 for said purpose, if necessary).

Through such structure, the degree of crooked (curvature) can change like the control circulation/repetitive mode that forms bar 21 '.For example, formation forms less bending at once than macrobending and at their middle bodies " fast " in their ends in the roll forming bar to allow bar 21 ' like this.Because the rapid action feature of actuator 50 and the effective and control characteristic of bending roll that comprises the location of

roller

62 and 63, the bending of variation can fast and accurately be carried out, though with the 2500-5000 foot/hour linear speed.Be noted that roller 63 given natural winding action around the motion of the axle of roller 62 to bar 21, because bar 21 is by around roller 62 " drawings " ..., thus the bending of formation receives excellent control thus, and mechanism is durable and firm.

When lower roller 63 is rotated around the axle of apex roller 62, can adjust the downstream that lower roller 63 keeps continuous bar 21 tightly to abut against the circumferential surface of apex roller 62 effectively.For this reason, apex roller 62 is sometimes referred to as " forming rolls ", and adjustable roller 63 is sometimes referred to as " pressing pressure roller " or " maintenance roller ".Recognize that when continuous bar 21 self partly is wrapped in around the apex roller 62 can adjust lower roller 63 can be used for continuous bar 21 clampings and the independent maintenance equipment of the circumference that is being held against (or near) apex roller 62 is replaced (or additional) potentially by design.For example, maintenance equipment can be stretching pin or the bar-shaped arm that below bar 21, extends separately, and delivers to roller 62 by part around the rotation of the roller 62 of axle, forms the small radii bending thus." tightly " but the bending long enough; Thereby when bar part 21 ' by when continuous bar 21 downcuts; Half crooked one of small radii forms the decline of (future) bar part 21 ', and another half one forms the first of (ensuing future) bar part 21 '.

Be appreciated that under the situation that does not break away from notion of the present invention, said structure to be changed and revise, and be appreciated that such notion intention covers by accompanying claims and cover, only if these claims are described by language in addition.

Claims

1. roll forming method, it may further comprise the steps:

Provide and have the high-strength material plate of the tensile strength of 80KSI at least;

The rolling formation apparatus that can form said plate of material with at least 900 feet/hours speed is provided; Said rolling formation apparatus comprises can adjust bending station, actuator and controller, and this controller operationally links to each other with the said bending station of rapid adjustment automatically to form differently curved radius with said bending station and the actuator adjusted; And

Said plate of material roll forming is had the continuous bar in continuous cross section with formation, in roll forming and near roll forming finishes, continue and repeatedly give differently curvedly, carry out said roll forming with at least 900 feet/hours linear speed simultaneously;

Said method comprises that also said continuous bar is cut into length and shape is suitable for the bar section as the bumper bracing piece;

The continuous bar of roll forming and give differently curved said step and comprise: form end parts with radius R 1 and the middle body with radius R 2 different with radius R 1, said each bar section has and is positioned at central authorities and middle body with radius R 2 and be positioned at two ends and have the end parts of radius R 1.

2. method according to claim 1, it comprises said controller programming to form differently curved along said continuous bar at the select location place.

3. method according to claim 2, it comprises provides shearing device, and based on the said shearing device of said differently curved position operation to form the bar section, have required bending at the end position place of said bar section.

4. method according to claim 3, it comprises said controller programming to control said shearing device with the synchronous mode of the control of said bending station and said rolling formation apparatus.

5. method according to claim 1, it comprises said controller programming to control said rolling formation apparatus with the synchronous mode of the control of said bending station.

6. roll forming method, it may further comprise the steps:

Provide and have the steel plate that intensity is suitable as the vehicle bumper bracing piece;

Provide to be the rolling formation apparatus of continuous bar with said steel formability; Said continuous bar has cross section and the intensity that is suitable as the vehicle bumper bracing piece; Said rolling formation apparatus comprises can adjust bending station, actuator and controller, and said controller operationally links to each other with said bending station and is used for adjusting automatically and apace said bending station to form differently curved radius; And

The continuous bar that said steel plate roll forming is had continuous cross section with formation; In said roll forming and near roll forming finishes; In the continuous said rolling formation apparatus of operation, continue and repeatedly use said bending station to give different bendings;

7. method according to claim 6, wherein said material have the tensile strength of 80KSI at least.

8. method according to claim 6, wherein said bending station comprise principal curvature roller and U-shaped framework, and this U-shaped framework supporting keeps roller to abut against said principal curvature roller to keep said continuous bar, and said actuator operationally links to each other with said U-shaped framework; Use the step of said bending station to comprise that the said actuator of operation is reciprocally to move said U-shaped framework and reciprocally to move said maintenance roller again to give various selected bendings to said continuous bar.

9. method according to claim 8, wherein said U-shaped framework are rotatably installed on the axle of said principal curvature roller, and said method comprise make said U-shaped framework around the axle rotation of said principal curvature roller to give various selected bendings.

10. method according to claim 8, it comprises each that utilize in said principal curvature roller of motor drive and the said maintenance roller.

11. method according to claim 8; It comprises the bridge that is positioned at the said maintenance roller upper reaches, and comprises such step: the said continuous bar of surface bearing is to reduce the uncontrolled bending of said continuous bar in said principal curvature roller front before said maintenance roller.